Custom 3-d orthotic device

ABSTRACT

An orthotic support assembly is disclosed herein that includes an internal device configured to be inserted within a person&#39;s footwear. The internal device is formed of a cushioning material and extends from an internal surface at a bottom portion of the footwear to an internal surface of a top portion of the footwear.

BACKGROUND

Orthotic devices are used to support a patient's foot during walking. Current orthotic devices include generally flat inserts that fit into a bottom of a patient's shoe to provide support to the patient. In some instances, flat orthotic devices are supplemented with auxiliary support devices such as ankle foot orthoses. Further orthotic devices include custom orthotic shoes formed to support the patient. These current solutions can be uncomfortable, inflexible, expensive and unforgiving, leading to undesirable outcomes.

SUMMARY

A custom 3-D orthotic device is disclosed herein that is configured to be inserted within a patient's shoe. The orthotic device includes a first portion supporting at least a portion of a sole of the patient's foot and a second portion that extends to a top of a user's foot.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is flow diagram of a method of forming a custom orthotic device.

FIG. 2 is a side view of a custom orthotic device.

FIG. 3 is a plan view of the custom orthotic device of FIG. 2.

FIG. 4 is an end view of the custom orthotic device of FIG. 2.

FIG. 5 is a perspective view of custom orthotic devices and corresponding shoes.

FIG. 6 is a schematic sectional view of a custom orthotic insert supporting a patient's foot within a shoe.

FIG. 7 is a schematic sectional view of a foot within a shoe.

DETAILED DESCRIPTION

FIG. 1 is a flow diagram of a method 10 for forming a custom orthotic insert or device for use with a patient's footwear, for example a conventional shoe or boot. At step 12, a patient's foot is scanned. The scanning can be based on pressure points on a bottom of the patient's foot (e.g., using an impression or pressure activated circuits) and/or optical capture of an overall shape of the patient's foot. In addition, the scanning can include identifying a position of one or more wounds on a patient's foot. At step 14, a shoe for the insert can be selected. The shoe can be any type or style and measured for use with the custom orthotic insert. Based on the scanning in step 12 and selection in step 14, method 10 proceeds to step 16, where a shape for different regions of the insert can be determined. For example, as discussed below, the shape can include a sole portion, a wedge portion, one or more openings and varying thicknesses throughout the orthotic insert. The orthotic insert is then formed at step 18, including the sole portion and wedge portion. Additionally, if needed, one or more openings in the orthotic can also be formed in the insert. Once the insert is complete, the insert can be positioned within the shoe at step 20.

FIGS. 2-4 show an example embodiment of an orthotic support insert or device 100 sized to be positioned within an external device such as a shoe, boot or the like that is formed in accordance with method 10 of FIG. 1. The device 100 includes a forefoot portion 102, a midfoot portion 104, a hindfoot portion 106 and a wedge portion 108 extending along a side of the midfoot portion 104. In one embodiment, the device 100 can be formed of a cushioning material (e.g., foam) that removes excess tolerance and is compressed between a user's foot and an inside portion of the shoe. Stated another way, the cushioning material of the device 100 contacts the top, side(s) and bottom of the foot and further contacts a top interior surface, a bottom interior surface and side interior surface(s) of the shoe. The wedge portion 108, in the embodiment illustrated, includes a vertical portion that extends upwardly along a side of the midfoot portion 104. Further, the wedge portion 108 includes a transverse portion that extends away from the vertical portion and terminates at a free end. At least a portion (i.e., the transverse portion) of the wedge portion 108 is positioned on a top of the user's foot during use. In other embodiments, the wedge portion 108 extends at least 1/2 way up a height of the patient's foot, at least 3/4 way up a height of the patient's foot or other heights to provide separation between the patient's foot and the corresponding shoe. To this end, the wedge portion 108 wraps around the patient's foot.

Wedge portion 108 can be positioned and configured in various ways. For example, wedge portion 108 may have a thickness of greater or lesser extent than the forefoot portion 102, midfoot portion 104 and/or hindfoot portion 106. In other embodiments, the wedge portion 108 can be positioned on an inside (medial aspect) of the foot, an outside (lateral aspect) of the foot or in other locations as desired. The wedge portion 108 is configured to establish an interior volume in select portions of the foot between a surface of a patient's skin and an internal surface of the patient's shoe. To this end, the location and extent of the wedge portion 108 can be selected as desired to establish the interior volume. As a result, wounds within the interior volume can have an enhanced opportunity to heal while the patient wears the orthotic device 100 within the shoe as movement between the patient's foot and the shoe is limited.

FIG. 5 illustrates various orthotic inserts 110, 120, 130 and 140 that can be formed using method 10 of FIG. 1. These inserts 110-140 are formed and associated with a selected shoe, such that a patient can have different inserts for different shoes. The inserts are illustrated with different sized wedge portions, as well as insole portions that extend a height above their respective sole portions. For example, a free end of respective wedge portions for the inserts 110-140 can terminate at different positions on top of the foot as desired.

With reference to FIGS. 6 and 7, in one embodiment, the orthotic insert 100 can be formed with an opening 200, which creates an interior volume V within the insert 100, effectively removing excess tolerance between a foot F and a corresponding shoe or boot 202 while suspending the wound W so that the shoe 202 can be utilized conventionally as the wound W heals. The volume V is bound by an edge surface 204 of the opening, a surface 206 of the skin of the foot inbound of the edge surface 204 and a surface 208 of the shoe 202 inbound of the edge surface 204. The interior volume V can be bound by at least one side of the foot F, at least two sides of the foot F, at least three sides of the foot F or all sides of the foot. In the embodiment illustrated, the interior volume V is bound by two sides of the foot F, namely a portion of a sole of the foot F (i.e., the bottom) and a portion of a muscular lateral ridge of the foot F (i.e., the outer side). In other embodiments, the volume V can include the bottom, the bottom and the inner side, the inner side and the top side, the outer side and the top side, the bottom, inner and outer sides, the top, inner and outer sides, or all sides. In further embodiments, multiple openings can be positioned within the insert 100.

Due to the presence of volume V, wound W is suspended within the insert 100 and protected from contact with shoe 202 during use of the insert 100 while a patient walks, stands or engages in other activity. A thickness of the insert 100 can be selected to ensure that ample space exists between the outer surface of the skin and the internal surface of shoe 202. In one embodiment, the thickness of the insert 100 is at least 1/8 inch, at least 1/4 inch, at least 1/3 inch, at least 3/8 inch, at least 1/2 inch, at least 5/8 inch, at least 3/4 inch, greater than 3/4 inch, between 1/8 and 1 inch and other thicknesses. In addition, a size of the opening (as defined by the edge surface 204) can be selected to provide ample space surrounding the wound W. As a result, forces placed on the foot F during walking, standing or other activity are distributed throughout the insert 100, while the wound W is exposed to little or no forces.

In the illustrated embodiment, opening 200 is positioned in the wedge portion 108 and positioned to surround a wound on an outer side of the patient's foot. The opening 200 is defined by the edge surface 204, which extends along a thickness of the insert 100. As a result, the wound W is suspended within the internal volume V. Forces on the shoe 202 are distributed about the insert 100 and away from the wound W. The wedge portion 108 contacts both a top interior surface of the shoe 200 and a side interior surface of the shoe 200. The forefoot portion 102, midfoot portion 104 and hindfoot portion 106 contact a bottom interior surface of the shoe 200.

Various embodiments of the invention have been described above for purposes of illustrating the details thereof and to enable one of ordinary skill in the art to make and use the invention. The details and features of the disclosed embodiment[s] are not intended to be limiting, as many variations and modifications will be readily apparent to those of skill in the art. Accordingly, the scope of the present disclosure is intended to be interpreted broadly and to include all variations and modifications coming within the scope and spirit of the appended claims and their legal equivalents. 

1. An orthotic support assembly, comprising an internal device formed of a cushioning material positioned within a person's footwear and extending from an internal surface at a bottom portion of the footwear to an internal surface of a top portion of the footwear.
 2. The orthotic support device of claim 1, wherein the cushioning material includes a wedge portion configured to be positioned along a side surface of the footwear and extend to the top portion of the footwear such that the cushioning portion contacts the internal surface of the top portion of the footwear.
 3. The orthotic support device of claim 2, wherein the cushioning material includes a forefoot portion, a midfoot portion and a hindfoot portion, the wedge portion extending upwardly from the midfoot portion.
 4. The orthotic support device of claim 3, wherein the wedge portion is positioned on a medial side of the footwear.
 5. The orthotic support device of claim 3, wherein the wedge portion is positioned on a lateral side of the footwear.
 6. The orthotic support device of claim 1, further comprising an opening positioned in the cushioning material, the opening creating an internal volume positioned between a foot and the internal surface of the footwear.
 7. A method, comprising: accessing cushioning material defining a forefoot portion, a midfoot portion, a hindfoot portion and a wedge portion extending upwardly from the midfoot portion; accessing a shoe; and positioning the cushioning material within the shoe such that at least a portion of the wedge portion will contact a top interior surface of the shoe.
 8. The method of claim 7, further comprising positioning the wedge portion on a medial side of the shoe.
 9. The method of claim 7, further comprising positioning the wedge portion on a lateral side of the shoe.
 10. The method of claim 7, further comprising positioning a foot in the shoe, the wedge portion positioned between a top of the foot and the top interior surface of the shoe.
 11. The method of claim 10, further comprising positioning an opening in the cushioning material, the opening creating an internal volume between the foot of the user and a side interior surface of the shoe.
 12. The method of claim 10, further comprising positioning an opening in the cushioning material, the opening creating an internal volume between the foot of the user and a bottom interior surface of the shoe.
 13. An orthotic insert, comprising: a forefoot portion; a midfoot portion; a hindfoot portion; and a wedge portion including a vertical portion extending from the midfoot portion and a transverse portion extending from the vertical portion and spaced apart from the midfoot portion.
 14. The orthotic insert of claim 13, wherein the wedge portion is formed of a cushioning material.
 15. The orthotic insert of claim 13, wherein the wedge portion is positioned on a medial side of the insert.
 16. The orthotic insert of claim 13, wherein the wedge portion is positioned on a lateral side of the insert.
 17. The orthotic insert of claim 13, further comprising an opening in the wedge portion. 